Method for enhancing the physico-chemical properties of bitumen compositions and novel bitumen compositions with enhanced properties and their uses

Abstract

The invention concerns method for enhancing the physico-chemical properties of bitumen compositions and novel bitumen compositions with enhanced properties and their uses by mixing a functionalized amorphous silica made by combining amorphous silica with a coupling agent.

1. A process for producing bitumen having improved physicochemical properties comprising the steps of:
 (a) combining amorphous silica with a coupling agent to produce a functionalized amorphous silica; and 
 (b) mixing the functionalized amorphous silica with bitumen. 
 
     
     
       2. The process of  claim 1 , further comprising the step of heating the bitumen to a temperature of between about 120° C. to about 190° C. prior to mixing the functionalized amorphous silica with the bitumen. 
     
     
       3. The process of  claim 2 , wherein the amorphous silica is a natural silica or a precipitated silica. 
     
     
       4. The process of  claim 3 , wherein the amorphous silica is functionalized using a coupling agent selected from the group consisting of silicon, an alkylsilicon, an aminosilicon, a thiosilicon, an epoxysilicon and mixtures thereof. 
     
     
       5. The process of  claim 4 , wherein the quantity of functionalized amorphous silica mixed with the bitumen is between about 0.01% and about 20% by weight compared to the weight of the bitumen formulation. 
     
     
       6. The process of  claim 5 , wherein the quantity of functionalized amorphous silica mixed with the bitumen is between about 0.1% and about 7% by weight compared to the weight of the bitumen formulation. 
     
     
       7. The process of  claim 5 , wherein the amorphous silica is a precipitated silica in the form of essentially spherical balls having an average size of at least 80 microns. 
     
     
       8. The process of  claim 7 , wherein the amorphous silica is a low water uptake silica. 
     
     
       9. The process of  claim 1 , further comprising the step of mixing an aggregate material with the bitumen. 
     
     
       10. The process of  claim 1 , wherein the quantity of coupling agent combined with the amorphous silica is between about 0.1% to about 30% by weight compared to the weight of the amorphous silica. 
     
     
       11. The process of  claim 10 , wherein the quantity of coupling agent combined with the amorphous silica is between about 5% to about 15% by weight compared to the weight of the amorphous silica. 
     
     
       12. The process of  claim 1 , wherein the bitumen is selected from the group consisting of asphalt, maltha, a natural bitumen, a pyrobitumen, an artificial bitumen, or mixtures thereof. 
     
     
       13. A process for producing an improved bitumen based coating comprising the steps of:
 (a) mixing bitumen, water and an emulsifier at ambient temperature to form a bitumen emulsion; 
 (b) adding to the bitumen emulsion an amorphous silica combined with a coupling agent to form a functionalized amorphous silica; 
 (c) spreading the bitumen emulsion containing functionalized amorphous silica to obtain a uniform coating; and 
 (d) breaking the bitumen emulsion. 
 
     
     
       14. The process of  claim 13 , wherein the amorphous silica is a natural silica or a precipitated silica. 
     
     
       15. The process of  claim 14 , wherein the amorphous silica is functionalized using a coupling agent selected from the group consisting of silicon, an alkylsilicon, an aminosilicon, a thiosilicon, an epoxysilicon and mixtures thereof. 
     
     
       16. The process of  claim 15 , wherein the quantity of functionalized amorphous silica mixed with the bitumen is between about 0.01% and about 20% by weight compared to the weight of the bitumen formulation. 
     
     
       17. The process of  claim 16 , wherein the quantity of functionalized amorphous silica mixed with the bitumen is between about 0.1% and about 7% by weight compared to the weight of the bitumen formulation. 
     
     
       18. The process of  claim 16 , wherein the amorphous silica is a precipitated silica in the form of essentially spherical balls having an average size of at least 80 microns. 
     
     
       19. The process of  claim 18 , wherein the amorphous silica is a low water uptake silica. 
     
     
       20. The process of  claim 13 , further comprising the step of mixing an aggregate material with the bitumen. 
     
     
       21. The process of  claim 13 , wherein the quantity of coupling agent combined with the amorphous silica is between about 0.1% to about 30% by weight compared to the weight of the amorphous silica. 
     
     
       22. The process of  claim 21 , wherein the quantity of coupling agent combined with the amorphous silica is between about 5% to about 15% by weight compared to the weight of the amorphous silica. 
     
     
       23. The process of  claim 13 , wherein the bitumen is selected from the group consisting of asphalt, maltha, a natural bitumen, a pyrobitumen, an artificial bitumen, or mixtures thereof. 
     
     
       24. A process for producing an improved bitumen based coating comprising the steps of:
 (a) heating a quantity of bitumen to a temperature of between about 120° C. and about 190° C.; 
 (b) adding to the heated bitumen an amorphous silica combined with a coupling agent to form a functionalized amorphous silica; 
 (c) mixing the bitumen/functionalized amorphous silica, water and an emulsifier to form a bitumen emulsion; 
 (d) spreading the bitumen emulsion containing functionalized amorphous silica to obtain a uniform coating; and 
 (e) breaking the bitumen emulsion. 
 
     
     
       25. The process of  claim 24 , wherein the amorphous silica is a natural silica or a precipitated silica. 
     
     
       26. The process of  claim 25 , wherein the amorphous silica is functionalized using a coupling agent selected from the group consisting of silicon, an alkylsilicon, an aminosilicon, a thiosilicon, an epoxysilicon and mixtures thereof. 
     
     
       27. The process of  claim 26 , wherein the quantity of functionalized amorphous silica mixed with the bitumen is between about 0.01% and about 20% by weight compared to the weight of the bitumen formulation. 
     
     
       28. The process of  claim 27 , wherein the quantity of functionalized amorphous silica mixed with the bitumen is between about 0.1% and about 7% by weight compared to the weight of the bitumen formulation. 
     
     
       29. The process of  claim 27 , wherein the amorphous silica is a precipitated silica in the form of essentially spherical balls having an average size of at least 80 microns. 
     
     
       30. The process of  claim 29 , wherein the amorphous silica is a low water uptake silica. 
     
     
       31. The process of  claim 24 , further comprising the step of mixing an aggregate material with the bitumen. 
     
     
       32. The process of  claim 24 , wherein the quantity of coupling agent combined with the amorphous silica is between about 0.1% to about 30% by weight compared to the weight of the amorphous silica. 
     
     
       33. The process of  claim 32 , wherein the quantity of coupling agent combined with the amorphous silica is between about 0.1% to about 30% by weight compared to the weight of the amorphous silica. 
     
     
       34. The process of  claim 24 , wherein the bitumen is selected from the group consisting of asphalt, maltha, a natural bitumen, a pyrobitumen, an artificial bitumen, or mixtures thereof.